INTEGRATED FLOW METER FOR ALUMINUM CASTINGS

Abstract

A molten metal laundering system includes a pump that draws molten metal from a reservoir. A heated raceway receives the molten metal from the pump and carries a flow of the molten metal. A conduit extends from the heated raceway and is exposed exterior the heated raceway. The conduit carries the flow. A temperature sensor senses a temperature of the molten metal in the conduit. An outlet at an end of the conduit directs the flow from the conduit into a casting mold. A flow meter is disposed along the conduit with the conduit extending through the flow meter. The flow meter senses a flow rate of the flow of the molten metal in the conduit. A control module adjusts operation of the pump based at least on the flow rate sensed by the flow meter and the temperature sensed by the temperature sensor.

Claims

1. A molten metal laundering system comprising: a pump configured to draw molten metal from a reservoir; a heated raceway configured to receive the molten metal from the pump and carry a flow of the molten metal; a conduit extending from the heated raceway and exposed exterior the heated raceway, the conduit configured to carry the flow of the molten metal; a temperature sensor configured to sense a temperature of the molten metal in the conduit; an outlet disposed at an end of the conduit and configured to direct the flow of the molten metal from the conduit into a casting mold; a flow meter disposed along the conduit, the conduit extending through the flow meter, the flow meter configured to sense a flow rate of the flow of the molten metal in the conduit; and a control module in communication with the pump, the control module configured to adjust operation of the pump to adjust the flow of the molten metal into the casting mold based at least on the flow rate sensed by the flow meter and the temperature sensed by the temperature sensor.

2. The molten metal laundering system of claim 1, wherein the flow meter includes a non-contact flow meter.

3. The molten metal laundering system of claim 2, wherein the conduit includes a non-magnetic material.

4. The molten metal laundering system of claim 1, wherein the flow meter includes a contact-based flow meter.

5. The molten metal laundering system of claim 4, wherein the conduit includes a non-magnetic metallic material.

6. The molten metal laundering system of claim 1, wherein the conduit is part of the heated raceway, a portion of the conduit extending from an end of the heated raceway to be exposed exterior of the heated raceway.

7. The molten metal laundering system of claim 1, wherein the conduit is part of the flow meter, a gasket disposed at an end of the conduit opposite the outlet configured to interface with the heated raceway.

8. The molten metal laundering system of claim 1, wherein an internal diameter of the conduit is different from an internal diameter of the heated raceway.

9. The molten metal laundering system of claim 1, wherein the control module is configured to adjust operation of the pump to achieve a target flow rate of the flow of the molten metal in the conduit.

10. The molten metal laundering system of claim 1, wherein the molten metal includes molten aluminum, the casting mold being for a vehicular component.

11. A computer-implemented method when executed on data processing hardware causes the data processing hardware to perform operations including: operating a pump of a molten metal laundering system to draw molten metal from a reservoir, a heated raceway receiving the molten metal from the pump and carrying a flow of the molten metal, a conduit extending from the heated raceway and exposed exterior the heated raceway, the conduit carrying the flow of the molten metal to an outlet at an end of the conduit, the outlet directing the flow of the molten metal from the conduit into a casting mold; receiving first sensor data from a temperature sensor, the first sensor data representative of a temperature of the molten metal in the conduit; receiving second sensor data from a flow meter, the flow meter disposed along the conduit, the conduit extending through the flow meter, the second sensor data representative of a flow rate of the flow of the molten metal in the conduit; and responsive to processing the first sensor data and the second sensor data, adjusting operation of the pump to adjust the flow of the molten metal into the casting mold based at least on the flow rate of the flow of the molten metal in the conduit and the temperature of the molten metal in the conduit.

12. The method of claim 11, wherein the flow meter includes a non-contact flow meter.

13. The method of claim 11, wherein the flow meter includes a contact-based flow meter.

14. The method of claim 11, wherein the conduit is part of the heated raceway, a portion of the conduit extending from an end of the heated raceway to be exposed exterior of the heated raceway.

15. The method of claim 11, wherein adjusting operation of the pump is based on a target flow rate of the flow of the molten metal in the conduit.

16. A system comprising: memory hardware storing instructions that, when executed on data processing hardware in communication with the memory hardware, cause the data processing hardware to perform operations comprising: operating a pump of a molten metal laundering system to draw molten metal from a reservoir, a heated raceway receiving the molten metal from the pump and carrying a flow of the molten metal, a conduit extending from the heated raceway and exposed exterior the heated raceway, the conduit carrying the flow of the molten metal to an outlet at an end of the conduit, the outlet directing the flow of the molten metal from the conduit into a casting mold; receiving first sensor data from a temperature sensor, the first sensor data representative of a temperature of the molten metal in the conduit; receiving second sensor data from a flow meter, the flow meter disposed along the conduit, the conduit extending through the flow meter, the second sensor data representative of a flow rate of the flow of the molten metal in the conduit; and responsive to processing the first sensor data and the second sensor data, adjusting operation of the pump to adjust the flow of the molten metal into the casting mold based at least on the flow rate of the flow of the molten metal in the conduit and the temperature of the molten metal in the conduit.

17. The system of claim 16, wherein the flow meter includes a non-contact flow meter.

18. The system of claim 16, wherein the flow meter includes a contact-based flow meter.

19. The system of claim 16, wherein the conduit is part of the heated raceway, a portion of the conduit extending from an end of the heated raceway to be exposed exterior of the heated raceway.

20. The system of claim 16, wherein adjusting operation of the pump is based on a target flow rate of the flow of the molten metal in the conduit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0015] FIG. 1 is a perspective view of a vehicle having a component formed via a casting process.

[0016] FIG. 2 is an exploded view of a launder system having an integrated flow meter.

[0017] FIG. 3 is an enlarged view of Area 3 in FIG. 2.

[0018] FIG. 4 is a schematic diagram showing the flow meter and pump of the launder system during a pump seasoning process.

[0019] FIG. 5 is a flow diagram of an example method for adjusting operation of the pump of the launder system during a casting process based on the flow rate sensed by the integrated flow meter.

[0020] Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

[0021] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

[0022] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles a, an, and the may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms comprises, comprising, including, and having, are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

[0023] When an element or layer is referred to as being on, engaged to, connected to, attached to, or coupled to another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on, directly engaged to, directly connected to, directly attached to, or directly coupled to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0024] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as first, second, and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

[0025] In this application, including the definitions below, the term module may be replaced with the term circuit. The term module may refer to, be part of, or include an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; memory (shared, dedicated, or group) that stores code executed by a processor; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

[0026] The term code, as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, and/or objects. The term shared processor encompasses a single processor that executes some or all code from multiple modules. The term group processor encompasses a processor that, in combination with additional processors, executes some or all code from one or more modules. The term shared memory encompasses a single memory that stores some or all code from multiple modules. The term group memory encompasses a memory that, in combination with additional memories, stores some or all code from one or more modules. The term memory may be a subset of the term computer-readable medium. The term computer-readable medium does not encompass transitory electrical and electromagnetic signals propagating through a medium, and may therefore be considered tangible and non-transitory memory. Non-limiting examples of a non-transitory memory include a tangible computer readable medium including a nonvolatile memory, magnetic storage, and optical storage.

[0027] The apparatuses and methods described in this application may be partially or fully implemented by one or more computer programs executed by one or more processors. The computer programs include processor-executable instructions that are stored on at least one non-transitory tangible computer readable medium. The computer programs may also include and/or rely on stored data.

[0028] A software application (i.e., a software resource) may refer to computer software that causes a computing device to perform a task. In some examples, a software application may be referred to as an application, an app, or a program. Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0029] The non-transitory memory may be physical devices used to store programs (e.g., sequences of instructions) or data (e.g., program state information) on a temporary or permanent basis for use by a computing device. The non-transitory memory may be volatile and/or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM)/programmable read-only memory (PROM)/erasable programmable read-only memory (EPROM)/electronically erasable programmable read-only memory (EEPROM) (e.g., typically used for firmware, such as boot programs). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM) as well as disks or tapes.

[0030] These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms machine-readable medium and computer-readable medium refer to any computer program product, non-transitory computer readable medium, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term machine-readable signal refers to any signal used to provide machine instructions and/or data to a programmable processor.

[0031] Various implementations of the systems and techniques described herein can be realized in digital electronic and/or optical circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

[0032] The processes and logic flows described in this specification can be performed by one or more programmable processors, also referred to as data processing hardware, executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit). Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto optical disks, or optical disks. However, a computer need not have such devices. Computer readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto optical disks; and CD ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

[0033] To provide for interaction with a user, one or more aspects of the disclosure can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touch screen for displaying information to the user and optionally a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to and receiving documents from a device that is used by the user; for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.

[0034] Referring now to the figures and the illustrated configurations depicted therein, a vehicle 10 includes one or more components formed via a metallic casting process (FIG. 1). For example, the vehicle 10 includes an engine block 12 formed from cast aluminum. That is, the engine block 12 (or one or more other components of the vehicle 10) is formed by dispensing molten aluminum 14 (FIG. 4) into a mold or package using casting techniques. Aspects of the casting process may utilize real time flow rate measurements of the molten aluminum 14 delivered to the mold from a casting delivery or launder system 100 (FIG. 2). As described further below, the launder system 100 includes a flow meter 200 integrated with or disposed inline with components and/or conduits of the launder system 100 to reliably determine the flow rate F.sub.14 of the molten aluminum 14 from the launder system 100 and adjust the flow rate F.sub.14 through the launder system 100 based on the readings from the flow meter 200. In some examples, the flow meter 200 may determine the flow rate F.sub.14 without the flow meter 200 directly engaging the molten aluminum 14 and/or without interrupting or segmenting the launder system 100 in a way that would cause leak points. Although described herein as determining the flow rate F.sub.14 of molten aluminum 14 through the launder system 100, it should be understood that the flow meter 200 may be configured to determine flow rates of any suitable molten metal through various casting delivery systems and/or other conductive fluids, such as alkali metals or charged chemical solutions, through conduits of various systems.

[0035] As shown in FIG. 2, the casting delivery system or launder system 100 includes a reservoir or bath 102 of molten metal, such as molten aluminum 14, and a pump 104 configured to draw the molten aluminum 14 from the reservoir 102. When operated, the pump 104 delivers a flow of molten aluminum 14 from the reservoir 102 to a fill port 106 at a first end 110 of a raceway or race track 108. The flow of molten aluminum 14 moves along a channel or passageway of the raceway 108 from the first end 110 toward a second end 112 of the raceway 108 opposite the first end 110. The raceway 108 may be heated to maintain or regulate the temperature of the molten aluminum 14 and thus maintain or regulate the viscosity and flow rate F.sub.14 of the molten aluminum 14.

[0036] In the illustrated example, the fill port 106 is disposed at the first end 110 of the raceway 108 and fluidly coupled to the raceway 108 with a gasket or interface plate 114 disposed between the fill port 106 and the raceway 108 to provide a sealed connection between the fill port 106 and the raceway 108. In some examples, the fill port 106 may be integrated with the heated raceway 108. When the pump 104 is operated to deliver molten aluminum 14 to the fill port 106, the fill port 106 may ensure that the channel or passageway of the raceway 108 is fully filled. As discussed further below, this may ensure accurate flow rate measurements at the flow meter 200.

[0037] A conduit or tube 116 extends from the second end 112 of the raceway 108 and is exposed exterior of the heated raceway 108. The conduit 116 may be an extension of the channel or passage of the raceway 108, such that the conduit 116 may be continuous from the first end 110 of the raceway 108 past the second end 112 of the raceway 108 and toward an outlet 120 at an end 118 of the conduit 116 distal from the second end 112 of the raceway 108. Thus, the conduit 116 is configured to carry the flow of molten aluminum 14 toward the outlet 120, with the outlet 120 configured to direct the flow of molten aluminum 14 from the end 118 of the conduit 116 and into the casting mold or package receiving the molten aluminum 14. A gasket or interface plate 122 may be disposed between and provide a sealed connection for mounting the end 118 of the conduit 116 at the outlet 120.

[0038] As shown in FIG. 3, the conduit 116 may include a separate tube that is fluidly coupled to the channel or passage of the raceway 108 at the second end 112 of the raceway 108. That is, an end 124 of the conduit 116 opposite the end 118 disposed at the outlet 120 is fluidly coupled to the raceway 108. A gasket or interface plate 126 may be disposed between the end 124 of the conduit 116 and the second end 112 of the raceway 108 for mounting the conduit 116 to the raceway 108 with a sealed fluidic connection. The conduit 116 separate from the raceway 108 may be part of the flow meter 200.

[0039] The flow meter 200 is disposed along the conduit 116 between the second end 112 of the raceway 108 and the outlet 120 and is configured to sense the flow rate F.sub.14 of the molten aluminum 14 flowing through the conduit 116. With the exposed conduit 116 integrated with the raceway 108, the flow meter 200 may be fixedly placed at the conduit 116, such as clamped onto the conduit 116 from opposing sides to substantially surround the conduit 116 and/or slidably disposed along the conduit 116 such that the conduit 116 extends through the flow meter 200. With the exposed conduit 116 attached to the second end 112 of the raceway 108, the conduit 116 may be part of the flow meter 200. Thus, the flow meter 200 and the conduit 116 may be removable from the launder system 100, such as for easier maintenance, for movement of the flow meter 200 between different systems, for swapping with flow meters having different flow rate sensitivities, and the like.

[0040] Moreover, the launder system 100 and/or the flow meter 200 includes a temperature sensor 128 configured to sense a temperature T.sub.14 of the molten aluminum 14 in the raceway 108 and/or the conduit 116. The temperature sensor 128 transfers sensor data representative of the temperature T.sub.14 and the flow meter 200 transfers sensor data representative of the flow rate F.sub.14 to a control module 130 of the launder system 100, such as via a wired or wireless communication link (e.g., over Wi-Fi). The flow meter 200 and the temperature sensor 128 may transmit analog signals representative of the temperature and flow conditions of the molten aluminum 14. As discussed further below, the control module 130 is in communication with the pump 104 and controls operation of the pump 104 to adjust the flow of the molten aluminum 14 into the casting mold based at least on the flow rate F.sub.14 sensed by the flow meter 200 and the temperature T.sub.14 sensed by the temperature sensor 128.

[0041] In other words, the flow meter 200 and/or the launder system 100 may include or be in communication with the control module 130 that includes data processing hardware 132 and memory hardware 134 in communication with the data processing hardware 132. The memory hardware 134 stores instructions that, when executed on the data processing hardware 132, cause the data processing hardware 132 to perform operations. For example, the control module 130 stores instructions for operating the pump 104 of the launder system 100 based on the flow rate F.sub.14 sensed by the flow meter 200, such as according to the method 500 of FIG. 5 discussed further below.

[0042] In some examples, the flow meter 200 is a contact-based flow meter where the flow meter 200 includes a probe that extends at least partially into the conduit 116 for determining the flow rate F.sub.14 of the molten aluminum 14 as the molten aluminum 14 flows past and interacts with the probe. In these examples, the conduit 116 may be part of the flow meter 200. Optionally, the flow meter 200 is a contact-based flow meter where the flow meter 200 operates to generate a magnetic field that crosses the conduit 116 and at least partially interacts with the molten aluminum 14. As a conductive fluid, the magnetic field induces eddy currents in the molten aluminum 14. The reactionary magnetic field produced by the eddy currents may generate an electric charge between opposing sides of the conduit 116, which may be sensed by electrodes of the flow meter 200 contacting the opposing sides of the conduit 116. Strength of the reactionary magnetic field may be correlated to the flow rate F.sub.14 of the molten aluminum 14 and may be detected based on the electric charge sensed by the flow meter 200. Thus, the contact-based flow meter 200 may utilize a conduit 116 formed from a non-magnetic metallic material, such as a tungsten-based alloy (e.g., ANVILOY) or a conduit 116 coated in a compatible material, such as a tungsten-coated stainless-steel conduit.

[0043] Optionally, the flow meter 200 may be a non-contact or contactless flow meter that does not directly engage the molten aluminum 14 and/or the conduit 116. For example, the flow meter 200 may operate to generate the magnetic field that crosses the conduit 116 and induces the eddy currents in the conductive molten aluminum 14. The non-contact flow meter 200 may be configured to sense a force of the reactionary magnetic field experienced at the flow meter. By way of example, the non-contact flow meter 200 may include a magnetic element coupled to a load cell and the load cell may be configured to sense the reactionary magnetic field interacting with the magnetic field. The force of the magnetic field may be calibrated to the flow rate of the molten aluminum 14 through the conduit 116. Sensing the force of the magnetic field produced by the molten aluminum 14 may provide a less noisy signal than sensing voltage in industrial environments like foundry settings. In these examples, the flow meter 200 may utilize a conduit 116 formed from a non-magnetic material, such as a non-magnetic metal or a non-metallic ceramic material.

[0044] In some examples, the internal diameter of the conduit 116 at the flow meter 200 may be different from an internal diameter of the heated raceway 108 to adjust the flow rate F.sub.14 of the molten material 14 to better suit the sensitivity or sensing range of the flow meter 200. For example, if the expected flow of the molten material 14 through the raceway 108 is faster than a desired flow through the flow meter 200, the conduit 116 may be widened at the flow meter 200 to slow the flow rate F.sub.14 of the molten material 14 through the flow meter 200. Similarly, if the expected flow of the molten material 14 through the raceway 108 is slower than a desired flow through the flow meter 200, the conduit 116 may be narrowed or necked at the flow meter 200 to increase the flow rate F.sub.14 of the molten material 14 through the flow meter 200. Although this may lead to turbulence in the flow of the molten material 14, cause a pressure change in the launder system 100, and/or cause a buildup of corundum in the conduit 116, the accuracy of the flow meter 200 may be increased.

[0045] Because the density and viscosity of the molten aluminum 14 changes based on temperature, the control module 130 may be calibrated to determine the flow rate F.sub.14 of the molten aluminum 14 based on sensor data captured by the flow meter 200 and the temperature sensor 128 during a calibration session. For example, the control module 130 may be calibrated at various temperatures of the molten aluminum 14 and based on the diameter of the conduit 116, expected flow rate of molten aluminum 14 from the reservoir 102 (e.g., based on voltage or power settings of the pump 104), based on a fill rate calculated from the volume of the casting mold, based on the type of molten metal or conductive fluid, and the like. The control module 130 may store the predetermined calibration curves to achieve precise measurement of the flow rate F.sub.14 with variations in the temperature T.sub.14 of the molten aluminum 14 during subsequent use of the launder system 100 following the calibration process.

[0046] In other words, during the calibration process, molten aluminum 14 is sent through the integrated launder system 100 at different temperatures T.sub.14 into a known volume as a function of time, and temperature-dependent calibration curves are generated for determining the flow rate F.sub.14 based on the signal output by the flow meter 200. The mass of the molding cast may be tracked as a function of time to determine the flow rate during the calibration process. Calibration curves may be determined at various molten aluminum temperatures and with the pump 104 operating at different rates. The calibration process may be executed for each flow meter 200 and launder system 100 pairing, on a regular basis at the launder system 100 to maintain tolerance standards, and/or after a rebuild of the launder system 100.

[0047] Referring to FIG. 4, the interface between the flow meter 200 and the heated raceway 108 may be gasket swappable, meaning that the flow meter 200 may be removed or swapped from the launder system 100, such as for use during a seasoning process of the pump 104. During the seasoning process, molten aluminum 14 is drawn from the reservoir 102 by the pump 104 and sent through the conduit 116 back to the reservoir 102 in a closed loop. This may occur at the launder system 100 or as shown, the flow meter 200 is used as a standalone unit for measuring the flow rate F.sub.14 of molten aluminum 14 generated by the pump 104. During the seasoning process, a range of voltages may be applied to the pump 104 to vary the flow rate F.sub.14 and the flow rates F.sub.14 measured by the flow meter 200 may be compared to expected values to determine if the pump 104 falls within or out of a predetermined operating specification.

[0048] FIG. 5 provides a flowchart of an exemplary arrangement of operations for a method 500 of operating the launder system 100 based on the flow rate F.sub.14 sensed by the flow meter 200, such as after seasoning of the pump 104 and following calibration of the control module 130. The method 500 may be executed by the control module 130, such as at the data processing hardware 132 based on operations stored in the memory storage hardware 134. At operation 502, the method 500 includes operating the pump 104 of the molten metal laundering system 100 to draw molten metal 14 (e.g., molten aluminum or other suitable molten metal and/or conductive fluid) from the reservoir 102. The heated raceway 108 receives the molten metal 14 from the pump 104 and carries the flow of the molten metal 14. The conduit 116 extending from the end 112 of the heated raceway 108 distal from the pump 104 carries the flow of the molten metal 14 to the outlet 120 at the end 118 of the conduit 116 distal from the heated raceway 108. The outlet 120 directs the flow of the molten metal 14 from the conduit 116 into a casting mold. At operation 504, the method 500 includes receiving first sensor data from the temperature sensor 128, where the first sensor data is representative of the temperature T.sub.14 of the molten metal 14 in the conduit 116. At operation 506, the method 500 includes receiving second sensor data from the flow meter 200 disposed between the end 112 of the heated raceway 108 and the outlet 120. The conduit 116 extends through the flow meter 200 (or optionally within or past or underneath or above the flow meter 200). The second sensor data is representative of the flow rate F.sub.14 of the flow of the molten metal 14 in the conduit 116. Responsive to processing the first sensor data and the second sensor data, the method 500 includes at operation 508 adjusting operation of the pump 104 to adjust the flow of the molten metal 14 into the casting mold based at least on the flow rate F.sub.14 of the flow of the molten metal 14 in the conduit 116 and the temperature T.sub.14 of the molten metal 14 in the conduit 116. For example, the pump 104 may be adjusted to achieve a target flow rate F.sub.14 of the molten metal 14 to the casting mold. Operation of the pump 104 may be continuously or episodically adjusted to maintain the flow rate F.sub.14 at or near the target based on the real time sensed flow rate F.sub.14 and real time sensed temperature T.sub.14 of the molten metal 14. Further, the target flow rate F.sub.14 may be adjusted during operation of the pump 104, such as based on a casting program performed by the launder system 100. The control module 130 may be programmed with predetermined calibration curves that account for density changes in the molten metal 14 based on temperature to adjust the flow.

[0049] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

[0050] The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.